Background


Of the many options and kits available we have chosen the South African Birkin - a kit which faithfully reproduces the beauty of Colin Chapman's original car and which you build up with component parts from the factory, adding in your choice of engine and transmission.



This holds true to the tradition of garden shed mechanics without requiring quite the level of welding skill, or CAD programming, that some of the amazing, home built clubman cars require. Or at least we hope not, as neither of us have done anything like this before.....



Saturday, December 24, 2011

Airbox

We spent a while looking at options and designs of airbox. The main requirement was to fit under the bonnet without too much metal work so that we could mount the filter internally. This should mean a reasonably quite induction noise which will be essential to pass the noise emmissions test. We have been a bit worried about this element as I used to have a modified Peugeot 205 GTI which ran throttle bodies and sounded a bit like a canal barge trying to achieve earth orbit, even at idle. Fortunately A T Power (who supplied the throttle bodies) had a link to a company called Reverie, which makes among other things carbon airboxes in a multitude of designs. After much measuring up and head scratching we settled on a model that fits the bill, the Zolder 65 with shallow baseplate option.
The next problem was mounting it - carbon fiber is not easy to cut, makes tonnes of very nasty dust and obviously is not cheap to replace if you get happy with the power tools. So we cut a template out of mdf wood to match the intakes and clamped it to the backplate. It was then straightforward to use a hole saw to make the apertures in the correct place and all was calm in the garage. It looks, although we are proud parents, bloody good....! We had to file down the quick release tabs so that they didn't stick up too far and then it was on to the next task - cutting the hole in the already painted bonnet. Eek!

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